TWI841565B - Kit having wall anchor assembly - Google Patents

Abstract

Wall anchors and positioning aids disclosed herein grant a user the ability to temporary hang or otherwise mount heavyweight objects, while also allowing for adjustment of at least one of the location and orientation of the assembly via the direct manipulation of the object.

Description

Set with wall anchor assembly 【Cross-reference to related applications】

This application is related to attorney docket number 80864WO003 assigned to the applicant, entitled Wall Anchors and Assemblies for Heavyweight Objects , the entirety of which is incorporated herein by reference.

Numerous products and devices exist for providing a mounting device (e.g., hook) on a wall, such as for hanging picture frames, mirrors, or the like. Conventional nails and screws may not always be a convenient solution, and may not provide adequate supporting strength in the wall, particularly in the case of drywall or other relatively weak, fragile wall panels. Other mounting devices avoid the use of conventional fasteners and their attendant disadvantages, but may still result in undue damage to the wall panels, require the use of conventional tools, or fail to consistently hold the desired weight.

Some embodiments of the present disclosure are generally related to self-locating wall anchor assemblies. The self-locating feature eliminates the need to calculate, measure, and mark the exact location of the wall anchor. This greatly simplifies the installation process by reducing the number of steps to accurately position and install an object. Many embodiments of the present disclosure do not require any additional installation tools.

In one embodiment, the present disclosure provides a wall anchor assembly, which includes: a wall anchor including a base plate and a first fork; a pillow frame having an adhesive structure on a main surface thereof; and a spacer having at least one detachable interface.

In another aspect, the present disclosure provides a wall anchor assembly comprising: a frame having a front surface and a rear surface, the frame including a guide on the front surface thereof configured to receive an insert plate, the insert plate including a load bearing structure; an anchor including a curved finger having a base, wherein the finger extends outwardly along an arc to an outer end through the wall; and a spacer pad attachable to a major surface of the insert plate, wherein the rear surface of the base includes an adhesive structure.

In yet another aspect, the present disclosure provides a wall anchor assembly comprising: a substrate including opposing major surfaces; a first insert plate pivotably coupled to an edge of the substrate at a first hinge section; a second insert plate pivotably coupled to the substrate at a second hinge section, the second hinge section being disposed at an edge of the substrate opposite the first hinge section; and an adhesive structure on a major surface of the substrate, wherein each insert plate includes a curved interdigital finger extending from a surface of the respective insert plate at a location distal to the hinge section.

In another aspect, the present disclosure provides a method for mounting an object, the method comprising: providing an anchor assembly as in any one of claims 1 to 33; temporarily attaching a rear surface of the assembly to a wall at a first position; placing the object on a load-bearing structure of the anchor assembly; directly manipulating the object so that the anchor assembly is disposed at a second position; and removing the object from the load-bearing structure.

As used herein, "layer" refers to a single layer, which may be continuous or discontinuous on a surface.

As used herein, "geometry" refers to the size and shape of a component.

The terms "preferred" and "preferably" in the embodiments of the present disclosure indicate that certain benefits may be provided under certain circumstances. However, other embodiments may also be preferred under the same or other circumstances. In addition, the reference to one or more preferred embodiments does not mean that other embodiments are not useful, nor is it intended to exclude other embodiments from the scope of the present disclosure.

In this application, terms such as "a/an" and "the" are intended to refer not only to singular entities but also to whole classes whose specific instances may be used as illustrations. The terms "a", "an", and "the" may be used interchangeably with the term "at least one". The phrases "at least one of" and "comprise at least one of" used after a list refer to any one of the items in the list and any combination of two or more items in the list.

As used herein, the term "or" generally includes "and/or" unless the context clearly indicates otherwise.

The term "and/or" means one or all of the listed elements, or a combination of any two or more of the listed elements.

Also herein, all numbers are assumed to be modified by the term "about" and preferably by the term "exactly". As used herein, the term "about" in conjunction with a measured quantity refers to the variation of the measured quantity as would be expected by a person skilled in the art making the measurement and exercising a degree of care commensurate with the measurement objective and the precision of the measurement equipment used.

Similarly, in this article, numerical ranges stated as endpoints include all numbers within the range and numbers stated as endpoints (for example: 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

As used herein, the term "generally" as a modifier of a characteristic or property, unless otherwise specifically defined, means that the characteristic or property is readily discernible by one of ordinary skill in the art, but does not require absolute precision or a perfect match (e.g., within +/-20% of a quantifiable characteristic). Unless otherwise specifically defined, the term "substantially" means a high degree of similarity (e.g., within +/-10% of a quantifiable characteristic), but again does not require absolute precision or a perfect match. It should be understood that terms such as identical, equal, consistent, constant, absolute, and similar are applicable to specific situations within common tolerances or measurement errors, and do not require absolute precision or a perfect match.

The above summary of the disclosure is not intended to describe every disclosed embodiment or every implementation of the disclosure. The following description more specifically illustrates illustrative embodiments. In several places throughout this application, guidance is provided through lists of examples, which may be used in various combinations. In various cases, the cited lists serve only as representative groups and should not be construed as exclusive lists.

5: Wall surface/wall

10: Wall anchor assembly/anchor assembly/assembly

20: Anchor assembly

30: Wall anchor assembly/anchor assembly/assembly

40: Wall anchor assembly/anchor assembly/assembly/anchor

60: Adhesive structure

80: Picture frame

90: ruler

100: Wall anchor/anchor

110: Anchor substrate/base/substrate/plate/frame

111: front surface/front side

112: Rear surface facing the wall/rear surface

113: Top edge/Upper edge/Bottom edge/Lower edge

114: bottom edge/lower edge/lowermost edge

115: Side edge/edge

116: Side edge/edge

120: Lower section/section/substrate section/lower frame section

121: Top edge/upper edge/lower section

122: Upper section/section/upper base section/upper plate section

123: Alignment notch/notch

127: Score line

130: Concave part

150: Curved fork/fork/insert

151: Wall base/interdigital base/base

151a: Top edge/Bottom edge

152: external end/external point/end/interdigital end

155: Height

156: interdigital side surface/side surface

158: Edge

159: end length

160: Linear handle/handle

161: Base of handle

162: External end

165: Angle

170: load bearing structure/load bearing protrusion/protrusion/hook/structure

172: Base/hook base

176: Remote

180: weight/porosity/anchor porosity

181: Strength

190:Arch-shaped tabs

200: Align pillow frame/pillow frame

211: front surface/front side

212: Rear surface/back side

215: Side edge

216: Side edge

220: Initial thickness/thickness

230: Width

240: Insert guide

250: Edge protrusion/interdigitation

300: Spacer pad/pad

310: front surface

320: Back surface

400: Object/Frame/Substrate

410: Frame body/body

411: front surface

412: Rear surface

413: Top edge

414: Bottom edge

415: Side edge

416: Side edge

430: Concave part

442: Rail/Side Rail

444:Guide wall

445: Overlay surface

448: Rails/Stop walls

450: Insert guide

490: Rotational pores

500: Insert plate/insert

510: Insert plate/front surface

511: front surface/front side

513: Top edge

550: Insert guide/guide hole

570: Load-bearing protrusion/load-bearing structure

590: Rotational pores

610: Substrate

619:Central horizontal axis/Central axis

621: Back surface

628: Hinge section

629: Hinge section

630: Upper insert plate/insert plate/upper plate

634: Remote edge

635: Side edge

636: Side edge

640: Lower insert plate/insert plate/lower plate

644: Remote edge

645: Side edge

646: Side edge

650: Curved fork/fork

652: Interdigitated external end

660: Curved fork/fork

662: Interdigitated external end

670: Load-bearing protrusion/load-bearing structure

670a: Upper section/load bearing section

670b: Lower section/load bearing section

700: Line

800: Transfer structure

810: Alignment feature

900: Picture frame/frame

910: D-ring recess

1000: Transfer structure

1010: First adhesive transfer structure/adhesive transfer structure/first adhesive structure/transfer structure/adhesive structure

1012: backing layer/backing

1014: Adhesive layer

1020: Second adhesive transfer structure/second adhesive structure/adhesive transfer structure/transfer structure/adhesive structure

1022: backing layer/backing

1024: Adhesive layer

1030: first connector component/separable connection/separable connector/first separable connection component/separable connection structure/first connection component/first separable connector component

1040: second connector member/second detachable connector member/second detachable connecting member/detachable connecting member/second connecting member

1080: Alignment of pores/pores

2000: Wall Anchor/Anchor

2010: Substrate

2011: Front surface

2012: Rear surface facing the wall/rear surface

2013: Top edge/Bottom edge

2014: Bottom edge

2015: Side Edges

2016: Side Edges

2050: downward curved fork/fork

D: Tip distance

P: plane/substrate plane/base plane/frame plane

The present disclosure will be further described with reference to the accompanying drawings, in which corresponding reference characters indicate corresponding parts throughout the several views, and in which: FIG. 1 is an exploded perspective view of a wall anchor assembly according to an embodiment of the present disclosure; and FIG. 2 is a perspective assembly view of the wall anchor assembly of FIG. 1; FIG. 3 is a perspective view of a wall anchor for use with the assembly of FIGS. 1-2; FIG. 4 is a front plan view of the wall anchor of FIG. 3; FIG. 5 is a side view of the wall anchor of FIGS. 3-4; and FIGS. 6A and 6B show FIG. 3 to FIG. 5 are side views of the wall anchors during and after being inserted into the wall; FIG. 7 is a perspective view of a wall anchor assembly according to another embodiment of the present disclosure; FIG. 8 is a perspective view of a plurality of wall anchor assemblies of FIG. 7 for aligning with markings on a wall; FIG. 9 is a perspective view of a wall anchor assembly according to another embodiment of the present disclosure; FIG. 10A to FIG. 10H are side views of the wall anchor assembly of FIG. 9 for mounting a frame to a wall surface; FIG. 11 is a perspective view of a wall anchor assembly according to the present disclosure; FIG. 12A to FIG. 12H show side views of the wall anchor assembly of FIG. 11 for mounting a frame to a wall surface; FIG. 13 shows a perspective view of a wall anchor assembly according to another embodiment of the present disclosure; FIG. 14 is a front plan view of the wall anchor assembly of FIG. 14; FIG. 15 is a side view of the wall anchor assembly of FIG. 14 to FIG. 15; FIG. 16 is a perspective view of the wall anchor assembly of FIG. 14 to FIG. 16, which is characterized in that the wall anchor assembly is inserted FIG. 17 is a teaching diagram showing the use of a wall anchor assembly according to another embodiment of the present disclosure; FIG. 18 is a perspective view of a transfer adhesive structure according to another embodiment of the present disclosure; FIG. 19 is a side cross-sectional view of the article of FIG. 18; FIG. 20 is a front perspective view of a wall anchor according to another embodiment of the present disclosure; FIG. 21 is a side view of the wall anchor of FIG. 20; and FIG. 22 is a front plan view of the wall anchor of FIG. 20 and FIG. 21.

The layers in some of the illustrated embodiments are for illustrative purposes only and are not intended to define the thickness (relative or otherwise) or absolute position of any component in an absolute manner. Although the above-mentioned figures illustrate several embodiments of the present disclosure, other embodiments mentioned in this specification are also contemplated. In all cases, the manner in which the present disclosure presents the present invention is representative and not limiting. It should be understood that a person of ordinary skill in the art may devise many other modifications and embodiments that still fall within the scope and spirit of the principles of the present invention.

Although the above-mentioned figures illustrate several embodiments of the present disclosure, other embodiments mentioned in this specification are also contemplated. In all cases, the manner in which the present disclosure presents the present invention is representative and not limiting. It should be understood that a person with ordinary knowledge in the art may devise many other modifications and embodiments that still fall within the scope and spirit of the principles of the present invention.

A wall anchor assembly 10 according to one embodiment of the present disclosure is depicted in FIGS. 1 and 2 . The wall anchor assembly 10 includes a wall anchor 100 and an alignment bolster 200. The wall anchor 100 includes a base 110 that is substantially rectangular in shape. A pair of upwardly curved fingers 150 extend from each side edge 115, 116 in a direction substantially orthogonal to a rear surface 112 (see FIG. 4 ). The fingers 150 extend to an outer end 152 that may be tapered to facilitate insertion when pressed into a wall panel. The alignment pillow frame 200 has an initial thickness 220 that is generally equal to or greater than the distance between the rear surface 112 and the outer end 152 of the curved interdigital fingers 150; the thickness 220 may be less than, equal to, or greater than the end length 159, depending on the compressibility or foldability of the pillow frame 200. The width 230 of the pillow frame is generally configured to be equal to or less than the spacing width between the interdigital fingers 150, allowing the interdigital fingers 150 to straddle the rear surface of the pillow frame and the wall anchor to abut the front surface 211 of the pillow frame 200 during use. In other embodiments, the width 230 may be greater than the spacing between the interdigital fingers 150, wherein the pillow frame 200 is compressible in the width direction or the pillow frame includes apertures to receive the interdigital fingers 150.

The pillow frame 200 may include a compressible material that decreases in volume upon light finger pressure (e.g., 0.2 to 1.5 MPa). The ratio of compressed volume to initial volume (i.e., compressibility) will vary depending on the compressible material used. As used herein, compressible materials may include elastic and/or inelastic materials, depending on whether the material substantially rebounds after the applied force is removed. The material may include any composition that allows it to have desired properties. Exemplary materials include foams (e.g., polymeric foams, including, for example, cellulose foams, glass foams, polymeric foams, and combinations thereof), sponges, nonwovens, glass fibers (e.g., glass wool), ceramic fibers, cotton fibers, cellulose fibers, felt, rubber, woven pads, nonwoven pads, drapes, and combinations thereof. The pillow frame 200 may be a single continuous layer of material or may include multiple materials configured in one or more layers.

The pillow frame 200 may also be foldable in that the through-thickness deformation in the direction of the wall is substantially permanent. Suitable foldable materials include corrugated paperboard, foldable foam, and other materials including at least partially destructible voids. The pillow frame may also feature one or more biasing elements including, but not limited to, deflection beams, leaf springs, plate springs, hinged springs, compression springs (e.g., standard, conical, etc.), torsion springs (e.g., single, double, etc.), extension springs, barrel springs, and the like.

The rear surface 212 of the pillow frame 200 may include an adhesive structure for temporarily securing the pillow frame 200 or the assembly 10 to a wall surface. In such embodiments, the rear surface of the assembly 10 is the surface of the adhesive structure that faces the wall. For example, the rear surface 212 may be coupled to a Command ^™ Adhesive Strip or a Command ^™ Picture Hanging Strip, both of which are available from 3M Company. In some embodiments, the adhesive structure may include a pressure-sensitive adhesive and a backing, while in other embodiments, the adhesive structure includes only a continuous or discontinuous layer of pressure-sensitive adhesive (i.e., no backing). A general description of useful pressure-sensitive adhesives can be found in Encyclopedia of Polymer Science and Engineering, Vol. 13, Wiley-Interscience Publishers (New York, 1988). Additional descriptions of useful pressure-sensitive adhesives can be found in Encyclopedia of Polymer Science and Technology, Vol. 1, Interscience Publishers (New York, 1964). Pressure-sensitive adhesive compositions are well known to those skilled in the art and have the following properties: (1) tack; (2) adhesion with no more than finger pressure; (3) sufficient ability to hold onto an adherend; and (4) sufficient cohesive strength to allow clean removal from an adherend. Materials that have been found to work well as pressure-sensitive adhesives are polymers designed and formulated to exhibit the necessary viscoelasticity resulting in a desired balance between tack, peel adhesion, and shear holding power. Suitable PSAs may be based on crosslinked or non-crosslinked (meth)acrylic polymers, rubbers, thermoplastic elastomers, silicones, polyurethanes, and the like, and may include tackifiers to provide the desired tack, as well as other additives. In some embodiments, the PSA is based on a (meth)acrylic PSA or at least one (meth)acrylate, wherein (meth)acrylate refers to both acrylate and methacrylate groups. In some embodiments, the PSA is based on an adhesive of an olefin block copolymer.

The adhesive structure used on the pillow frame 200 may be peelable or stretchable. In embodiments featuring a stretchable release structure, the structure can be removed from a surface by stretching at an angle less than 35°. In embodiments featuring a peelable release structure, the adhesive can be removed from a wall surface by stretching at an angle of 35° or greater. In some embodiments, the releasable adhesive can be removed by a combination of stretching and peeling release mechanisms.

The pillow frame 200 featuring one or more stretch release adhesive configurations may include, for example, any of the adhesives and configurations described in any of the following patents: U.S. Patent No. 5,516,581 (Kreckel et al.); U.S. Patent No. 6,231,962 (Bries et al.); U.S. Patent No. 7,078,093 (Sheridan et al.); and U.S. Patent No. 6,395,389 (Lühmann et al.), all of which are incorporated herein by reference in their entirety.

The pillow frame 200 featuring one or more peelable adhesive structures may include, for example, any of the adhesives and structures described in any of the following patent applications: International Publication Nos. 2015/035556, 2015/035960, U.S. Patent No. 9,894,931, and PCT Application Nos. US2017/015163 and US2017/014733, all of which are incorporated herein by reference in their entirety.

The adhesive construction may further include one or more release liners. The release liners may be, for example, on either or both of the major surfaces of the adhesive layer. The release liners protect the adhesive during manufacturing, shipping, and prior to use. When a user desires to use the adhesive construction, the user may peel off or remove the release liners to expose the adhesive. Examples of suitable liners include paper (e.g., kraft paper) or polymer films (e.g., polyethylene, polypropylene, or polyester).

In presently preferred embodiments, the adhesive construction is at least one of positionable and repositionable. As used herein, "positionable" means that an adhesive construction can be placed against a substrate surface and easily slid over the surface to a suitable position without pre-adhering or adhering the adhesive article to the substrate; pressure is generally required to adhere the adhesive construction to the substrate. As used herein, "repositionable" means that an adhesive article can be applied to a substrate, then removed and reapplied without distorting, damaging, or destroying the adhesive construction, or the substrate; a repositionable adhesive need not be positionable, or vice versa. Such adhesives allow the pillow holder 200 to be slid over or easily removed from a wall surface until sufficient pressure is applied to form an applied bond between the adhesive and the wall surface.

In addition to positionable and repositionable adhesive formulations (e.g., microsphere adhesives described in U.S. Patent No. 8,318,303 to Lu), adhesive configurations can be made at least one or more positionable or repositionable by engineered elements or surface features on the surface of the adhesive facing the wall. The engineered elements can act as spacers between the adhesive surface and the wall to prevent full contact and penetration of the adhesive, whereby an article can be initially positioned or rotated by sliding the protruding surface across the wall surface. Under certain conditions, the article can even be removed from the wall and placed at a new location. Once a location is selected, the separation created by the engineered elements can be overcome by applying sufficient pressure; the adhesive can contact and adhere to the wall. Engineered elements may include protruding adhesive "pegs" or "posts" (see, for example, Nos. 5,296,277 (Wilson et al.) and 5,795,636 (Keller et al.)), discrete, partially embedded particles, discrete clusters of protruding particles (such as ceramic microspheres), non-adhesive islands (including a weakening material), and combinations thereof. These elements protrude at least partially from the adhesive surface. A protruding element represents a departure or deviation from the average height of an otherwise planar surface area. Any of the protruding engineered elements may be combined with an intrusive feature. An intrusive feature (e.g., a recessed feature) may be generally described as a feature having a surface point located below an average height of the adhesive surface. In other embodiments, an intrusive feature may be used in the absence of a protruding feature. Additional information regarding positionable and repositionable adhesive configurations may be found in International Application No. PCT/US19/31339 assigned to the present applicant and incorporated herein by reference in its entirety.

A wall anchor 100 according to one embodiment of the present disclosure is depicted in FIGS. 3-5 . The wall anchor 100 includes a base 110 that exhibits a generally rectangular shape (as seen in FIG. 4 ). The base 110 includes a front surface 111 that is opposite a rear surface 112 that faces the wall; a top edge 113; a bottom edge 114; and opposite side edges 115, 116 that connect the top edge 113 and the bottom edge 114 to define an outer plate perimeter. A pair of curved fingers 150 extend from each side edge 115, 116 in a direction generally orthogonal to the rear surface 112 (see FIG. 3 ). The fingers 150 extend to an outer end 152 which may be tapered to facilitate insertion when pressed into a wall panel.

The base 110 includes a lower section 120 including a bottom edge 114 and an upper section 122 adjacent a top edge 113. The sections 120 and 122 are generally coplanar and include front surfaces that reside in a plane "P". The lower section 120 includes an open-ended area or recess 130 that is configured to be substantially aligned with the center axis of the substrate. The recess 130 substantially corresponds to the width of the load-bearing structure 170 in at least a width dimension. When viewed in a plane perpendicular to the substrate plane "P", the substrate 110 has an overall substantially rectangular shape. In other embodiments, the substrate 110 presents another shape or combination of shapes in the same viewing direction, including a circle, an oval, a triangular tetrahedron, a Y-shape, etc. Other variations may be envisioned and discerned by one of ordinary skill in the art.

The upper base section 122 includes an alignment notch 123 near the top edge 113 for visually confirming the placement and orientation of the anchor 100 on a wall surface. The upper section 122 is removably coupled to the lower section 120 via a score line 127. The score line 127 may include perforations, recesses, voids, combinations thereof, and other features that can selectively reduce the structural integrity of a material. The score line 127 allows the upper section 122 to be removed from the base plate 110 before or after the anchor 100 is secured to a wall surface, providing unconstrained access to the load bearing structure 170. The upper section 122 may also be hinged at the score line to improve the strength of the base plate 110 between the fingers 150. The presence of the upper section 122 prior to insertion may enhance the rotational force available to the user during installation, due in part to the increased height of the base plate 110 (e.g., the distance between the top edge 113 and the bottom edge 114).

The lower frame section 120 includes a pair of curved fingers 150 adjacent the top edge 121 and a pair of linear handles 160 adjacent the bottom edge 114. The fingers 150 and handles 160 each extend to an outer end 152, 162 over a length that is substantially equal to or less than the thickness of the wall to which the anchor is typically attached. The lengths of both the fingers 150 and handles 160 can be varied to allow for the selection of a particular thickness of wall, with the curved fingers 150 typically having a linear length or arc length that is at least twice that of the handles 160. The exemplary anchor 100 may also be useful without the handle 160, but multiple insertion points may improve the stability of the anchor 100 during installation, use, and removal.

The curved fingers 150 may have a constant radius of curvature or may have a varying radius of curvature at different points along the outer contour of the fingers 150, either discretely or continuously, from the wall base 151 to the outer end 152. The curvature produces a tip distance "D" from the top edge 151a of the finger base 151 to a plane parallel to the outer end 152, wherein greater curvature produces greater tip distance D. While not wishing to be bound by theory or relationships with gypsum wallboard, it is believed that increasing the tip distance results in an increase in the weight that can be installed on the anchor 100. In an exemplary embodiment, the tip distance D is approximately 0.15 inches. In the depicted embodiment, the fingers 150 are curved upward because the ends 152 are closer to a plane including the top edge 113 of the substrate 110 than the top edge 151a. In other cases, one or more of the fingers may include a downward curve (e.g., FIGS. 20-22 ).

The fingers 150 may include one or more flat surfaces and may include different cross-sectional shapes and combinations of shapes (e.g., rectangular, circular, oval, triangular, etc.). For example, the upper surface of a finger may be circular with a flat bottom surface to prevent cracks in the wall from propagating. Flat surfaces may also help prevent pullout due to stress concentrations in the wall. In the embodiment depicted in Figures 1 to 6, each finger 150 includes opposing, substantially flat side surfaces 156, each extending in a plane that is substantially orthogonal to the base plane "P". In other embodiments, one or both edges 158 of the fingers may be saw-toothed.

Each of the fingers 150 includes a height 155 and a thickness at the base 151. The thickness is measured in a direction parallel to the top edge 113 (e.g., the x-direction) and corresponds to the distance between the side surfaces 156 of the fingers. The comparison of the height 155 to the thickness defines an interdigital aspect ratio. In currently preferred embodiments, the aspect ratio is at least 3:1, at least 4:1, at least 5:1. In an exemplary embodiment, the height 155 can be approximately 0.10 inches and the thickness can be approximately 0.022 inches, resulting in an interdigital aspect ratio of 4.55:1. As further described below, the relatively thin nature of the interdigital fingers 150 reduces the required insertion force, and the wall itself acts to prevent the interdigital fingers 150 from buckling during insertion. Relying on the wall to prevent buckling allows the anchor to hold progressively heavier objects. The curved fingers 150 may taper in height over all or part of the arc length from the base 151 to the end 152.

Without wishing to be bound by theory, the aspect ratio of the fingers can alter the failure mode of the anchor by increasing the strength of the fingers in the load bearing direction (e.g., toward the bottom edge 113). The increased strength acts to resist bending in the fingers when mounting progressively heavier objects, which may cause the wall panel to fail before the fingers bend. Relatively high aspect ratio fingers can therefore perform in a manner consistent with user expectations of more common mounting hardware (e.g., nails, screws, etc.) while still reducing the effort required for installation.

The handle 160 forms an angle 165 with the rear surface 112 of the base. For example, the angle 165 (e.g., taken relative to a plane parallel to the frame plane "P") can be between about 75 degrees and about 90 degrees (e.g., between about 80 degrees and about 90 degrees or between about 85 degrees and about 90 degrees), although variations are possible. In a presently preferred embodiment, the handle 160 extends generally along a plane substantially orthogonal to the frame plane "P". Without wishing to be bound by theory, providing an excessively sharp angle between the handle 160 and the rear surface 112 will generally shear the gypsum wallboard. However, a slightly sharp angle (e.g., an angle 165 of 80 degrees or more) can facilitate insertion of the anchor 100 and, in some embodiments, aid in pulling the rear surface 112 substantially parallel to the wall. A shank may also be oriented at an angle so that the shank base 161 is not parallel to the lower edge 114 or either of the side edges 115, 116. In some cases, this orientation may improve the shear holding power of the anchor.

In the illustrated embodiment, and as can be particularly clearly seen in FIGS. 1 , 3 , and 4 , the fingers 150 and stem 160 can be formed from a single piece of material that has been bent or otherwise hinged at selected locations to form both the base section 120, the fingers 150, and the stem 160. Thus, each of the fingers 150 and stem 160 includes at least one section that is integral and substantially coplanar with the side edges 115, 116 of the frame 110. In other embodiments, one or more of the fingers and stem can be welded, fused, or otherwise attached to the rear surface 112 of the frame 110 at the edges 115, 116 or other locations spaced from the recess 130. When provided to the user, either the fork finger 150 or the handle 160 may be pre-hinged, or the user may choose to bend each of the components that penetrate the wall according to the user's preference.

As depicted, both the fingers 150 and stems 160 extend to coplanar endpoints, and the fingers 150 each include the same radius of curvature. In an alternative embodiment, either of the fingers 150 may be offset from the other along the length of the respective edge 115, 116 such that one finger base 151 is closer to the top edge 113 than the other. Furthermore, the substrate 110 may include one or more fingers in addition to the depicted pair of fingers 150; such additional finger(s) may be characterized by the same or different radius of curvature, height-to-thickness ratio, or location alongside the side edge 115, 116 or rear surface 112 of the substrate 110.

The load-bearing protrusion 170 extends outward from the front surface 111 of the substrate 110. As shown, the load-bearing protrusion 170 includes a hook at a base 172. The load-bearing structure used on the plate 110 may alternatively include a button, a lug, a handle, or any number of load-bearing structures for hanging items. In addition, the anchor 100 may include two or more load-bearing structures that are aligned along a longitudinal axis, a transverse axis, or both. In other embodiments, the front face of the substrate may be characterized by an adhesive layer (described in further detail below). As can be seen in Figures 3 and 4, the protrusion 170 is disposed on the front surface 111 so that the hook base 172 is positioned above the bottom edge 151a of the interdigitated base 151. However, it should be understood that the protrusion 170 may be placed at any desired location on the front surface 111, although such an arrangement may reduce the shear holding capability of the anchor and limit the types of objects that may be mounted in a desired manner.

Like the fingers 150 and the handle 160, the load-bearing protrusion 170 may be formed from a single piece of material that has been bent or otherwise hinged at selected locations to form both the substrate segment 120 and the load-bearing structure 170. As depicted, the hook 170 may be created by cutting (e.g., stamping, laser cutting, etc.) a portion of the substrate 110 along a path to form a hook profile, which may then overlap in the direction of the top edge 113 to form the protrusion.

Referring to Figures 6A and 6B, a method for attaching a wall anchor 100 to a substantially vertical surface is illustrated. In a first step, the upper plate section 122 is positioned at a desired location on the wall, optionally using alignment notches 123. The anchor 100 is rotated approximately 45 to 60 degrees so that the outer ends 152 of each curved fork finger 150 extend horizontally toward the wall and the outer point 152 is located at a desired entry point. A force is applied in a direction orthogonal to the front face 111 of the lower section 120. The applied orthogonal force causes the anchor to rotate about the upper edge 113 and the outer ends 152 of the fork fingers 250 penetrate the wall panel. Further rotation causes the remaining length of the fork finger to be driven into the wall board, followed by the insertion of the handle 160 until the rear surface 112 of the base plate 110 is substantially flush with the wall. Optionally, the upper section 122 may then be removed along the score line 127. Notably, the hook base 172 is substantially aligned with or spaced above the insertion point of the fork finger end 152 on the wall.

An object may be secured to the load bearing projection 170 either before or after the anchor 100 has been inserted into the wall. Once an object is on the hook 170, it has a weight 180 which creates a moment in a rotational direction away from the wall and downward. This translates into a force 181 which provides an outward deflection or thrust of the curved fingers 150. This force also operates around the lowermost edge 114 of the anchor 100 which acts like a pivot. The smaller the distance between the curved fingers 150 and the pivot point, the greater the force 181 pushing the anchor away from the wall. However, as can be seen with the anchor 100, this force is distributed across the core of the wall panel over the curved fingers 150. Distributing the force over the fingers 150 provides a significant amount of material for the fingers to penetrate. As a result, the anchor 100 is less likely to break free from the wall or cause significant damage to the wall panels.

To remove, the base plate can be lifted upward by the lower section 121. The upper edge 113 (or 121 if the upper section 122 is removed) naturally pivots on itself and the anchor is released as the outer ends 152 of the fingers 150 exit the wall. The lower section 120 may feature structure at the lower edge 113 to aid in removal, such as a protrusion that can be engaged by a screwdriver, key or other implement, or an engaging tab that can be engaged by a human finger.

In the currently preferred embodiment, the anchor is made of a metal material, however, it is understood that other suitable materials may be used. Anchor 100 is generally made of a resilient metal or metal alloy such as stainless steel, titanium, cobalt-chromium alloy (such as those manufactured by Elgiloy Specialty Metals, Elgin, IL) or a shape memory alloy such as an alloy of nickel and titanium (e.g., Nitinol). Preferably, anchor 100 is sufficiently resilient that the relaxed shape does not change significantly during the process of installing an object. Alternatively, anchor 100 may be made of any other resilient material known to those of ordinary skill in the art, such as a flexible polymer or composite material. Furthermore, although anchor 100 is specifically discussed as being mountable to a gypsum wallboard wall, it may be used with walls of other materials, or to secure an object to something other than a wall.

To use the assembly 10, the user first removes any release liner from the adhesive construction on the back 212 of the pillow frame 200 (if present). The pillow frame 200 and anchor 100 are then placed in the desired location and secured to the wall surface using finger pressure in the direction of the wall. Once the user is satisfied with the position of the pillow frame 200, light finger pressure is applied to the front face 211, which causes the pillow frame 200 to compress and the outer ends 152 of the fingers 150 to pierce the wall panel. The user can then separate the anchor from the pillow frame 200 and remove the pillow frame 200 from the wall (if it is adhesively secured). Using the markings as a guide, the user can install the anchor 100 generally as described with respect to Figures 6A and 6B.

A variation on anchor assembly 10 is depicted in FIGS. 7 and 8 . Anchor assembly 20 features a larger alignment bolster 200 compared to the width and height dimensions of anchor 100. It will be appreciated that many other aspects of anchor assembly 20 may have form and function similar to that described with respect to anchor 100 and such need not be repeated.

As depicted in FIG. 7 , the alignment pillow 200 includes two insertion guides 240 spaced across the width 230 of the pillow 200, wherein each insertion guide is adjacent to the side edges 215, 216. The insertion guide 240 includes an aperture extending through the thickness of the pillow 200. Each aperture is sized to allow a curved fork 150 on the anchor 100 to reach the intended wall surface when the pillow 200 is compressed. The alignment pillow 200 further includes edge protrusions 250 extending to form a top surface, a bottom surface, and a side surface. The edge protrusions 250 are designed to help a user orient, position, and level the anchor assembly 20 prior to insertion. As depicted in FIG8 , the edge protrusion may also aid in measuring to accurately locate an object (e.g., a picture frame) by serving as a rest for a ruler 90 or other measuring instrument. Although depicted as being similar to a prism, the edge protrusion may be any suitable shape or combination of shapes. The bolster 200 of the anchor assembly 10 or 20 may include an alignment notch (not shown) at one edge thereof, the location of which corresponds to the alignment notch 123 on the wall anchor 100.

In alternative embodiments of the present disclosure, a cradle may be sized and configured to receive other wall anchors and known fasteners in addition to or in place of anchor 100. For example, the cradle may be configured for assembly with anchors characterized in: U.S. Patent Nos. 8,414,239 (McDuff); 3,298,651 (Passer); and 3,966,157 (Corral et al.). Further exemplary anchors include those in: U.S. Patent Publication Nos. 2017/0002973 (Will et al.); 2015/0297002 (Long); and 2007/235622 (Barran et al.). Other anchor structures and assemblies may be used in conjunction with the pillow frame and will be apparent to one of ordinary skill in the art.

Turning now to FIGS. 9 and 10A-10H, an additional component for use with the anchor assembly of the present disclosure is depicted. Anchor assembly 30 includes wall anchor 100, alignment pillow 200, and spacer pad 300. It should be understood that many aspects of wall anchor 100 and pillow 200 have form and function similar to those described with respect to anchor assemblies 10 and 20, and such need not be repeated to those of ordinary skill in the art.

The spacer pad 300 includes a front surface 310 and a rear surface 320. The spacer pad 300 is received on the front surface 111 of the anchor 100, aligned with the bottom edge 114, and resides below the base of the load bearing structure 170. The pad 300 has a thickness that is greater than the shortest distance between the distal end 176 of the load bearing structure 170 and the front surface 111 of the anchor base 110, so that the pad 300 extends outwardly beyond the outermost edge of the structure 170. Although the spacer pad 300 is depicted as a separate structure, the spacer pad can also be integral with the pillow frame to create a recess or bracket for receiving a wall anchor. The spacer pad 300 is generally made of the same type of material as the pillow frame 200, but may be made of any suitable material capable of maintaining a shape in two or more dimensions.

Both the front surface 310 and the rear surface 320 of the discrete spacer pad 300 may include a removable interface, which may include any of the adhesive structures described above. The removable interface allows the spacer pad 300 to be repeatedly separated from either or both of an object to be mounted and a wall anchor. The removable interface allows the pad to be separated and connected along a general plane. In some embodiments, the removable interface may include, for example, mechanical fasteners including an interlocking system, a mutual clamping system with a connection without visible mechanical deformation or interference, releasable contact responsive fasteners, a separable structure, and the like. Suitable removable interfaces are discussed, for example, in U.S. Patent No. 9,920,783 (Runge et al.). In the currently preferred embodiment of the anchor assembly 30, each removable interface is a removable adhesive of the type described above.

A method of using the wall anchor assembly 30 is illustrated in FIGS. 10a-10h. In a first step, the anchor 100 is coupled to the bolster 200 such that the rear surface 112 of the base 110 contacts (or is close to) the front surface 211 (FIG. 10A). The spacer pad 300 is attached to the front surface 111 of the anchor base 110 (FIG. 10B). One or both of these steps may be performed by the manufacturer or retailer so that the user is not involved in the initial assembly. Next, the mounting object (as depicted, the picture frame 80) is placed on the load bearing structure via, for example, wires, brackets, or D-rings (FIG. 10C), and the front surface 310 of the pad 300 is attached to the object (FIG. 10D). If the mounting object includes a wire, it is presently preferred to tighten the wire on the load bearing structure 170. The user can position and orient the assembly at the desired location on the wall surface 5 by directly moving (e.g., sliding or rotating) the mounting object. Once the user is satisfied with the position of the object after one or more movement steps, the user applies pressure to the object to adhere the assembly 30 to the wall 5. If a repositionable adhesive is used, the user may choose to first secure the pillow frame to the wall and then move the assembly to the desired location. The object is then decoupled to form the load bearing structure 170, and the assembly 30 is maintained at the desired location on the wall (Figure 10E). After confirming that the assembly 30 is in the correct position and orientation, the user removes the spacer pad 300 and presses the outer end 152 of the interdigital finger into the wall 5. (Figure 10F). Alternatively, the spacer pad 300 can be removed after the initial interdigital marking step. Further disassembly of the anchor 100 and the pillow frame 200 allows the anchor 100 to be rotatably inserted into the wall 5 at the position corresponding to the earlier mark. (Figure 10G). Once the anchor is substantially flush with the wall 5, the object 400 can be secured to the load bearing structure 170 again (Figure 10H).

The anchor assembly 30 is particularly advantageous for large objects, such as picture frames, because a user can position the object at or near a desired location and temporarily secure the object to a wall surface. Temporary attachment reduces the guesswork and repeated attempts that typically accompany the installation of large objects. Additionally, the user can directly manipulate the object without having to rely on indirectly adjusting anchors or other hardware.

Turning to FIG. 11 and FIG. 12A to FIG. 12H, another embodiment of a wall anchor assembly 40 according to the present disclosure is depicted. The wall anchor assembly 40 includes a frame 400 and an insert plate 500. The frame 400 includes a guide characterized by rails 442, 448, which cooperates with the frame body 410 to define a recess 430. The recess 430 includes a continuous backing plate so that when the anchor assembly 40 is assembled, a portion of the frame 400 is disposed between the insert 500 and the wall. The insert 500 includes a load bearing protrusion 570 and is sized to slidably engage the guide. The assembly 40 further includes a spacer pad 300 and an anchor 100. Unlike previous embodiments, anchor 100 lacks a load bearing structure and instead includes an aperture 180 sized to receive a load bearing projection 570 on insert plate 500. It will be appreciated that many other aspects of anchor assembly 40 have form and function similar to those described with respect to anchor assemblies 10, 20, and 30, and similar aspects need not be repeated to one of ordinary skill in the art.

The frame 400 includes a generally flat body 410 having a front surface 411, a rear surface 412, opposing top and bottom edges 413 and 414, and opposing side edges 415, 416. The front surface 411 resides in a first frame plane, and the rear surface 412 resides in a plane parallel to the front plane. The frame body 410 is generally rectangular when viewed in a plane perpendicular to the first frame plane. However, in alternative embodiments, the frame body may present another shape or combination of shapes, including circular, oval, triangular, tetrahedral, Y-shaped, etc. The rear surface 412 of the frame 400 may include an adhesive formation 60 for temporarily attaching the frame 400 and the assembly 40 to a wall surface.

The guide extends around at least a portion of the periphery of the frame and includes opposing rails 442 integral with the side edges 415, 416 and a stop wall 448 extending along the bottom edge 414 of the body 410. The rails 442 are coupled to respective sections of the frame via guide walls 444, which are substantially arranged perpendicular to the first frame plane. Each rail 442 is spaced from the first frame plane according to the height of the guide wall 444, which corresponds substantially to the thickness of the insert 150.

Rails 442 serve to receive and guide insert 500 into the bottom of recess 430, while bottom stop wall 448 serves as a stop surface or detent to prevent slide of insert 500 in the direction of bottom edge 414. As depicted, each rail 442 extends the full length of recess 430 to top edge 413 of frame body 410. Stop wall 448 may be centrally located on the third section and not connected to any of the side rails 442. In other embodiments, one or both side rails 442 may extend only a portion of the length of the recess; in the same or other embodiments, stop wall 448 may extend the full width of bottom edge 414.

The rail 442 extends over and into the recess 430 to form an overlap surface 445 that faces the frame plane "P". Although this is not strictly necessary, the stop wall may also extend over and into the recess 430. When the anchor 40 is assembled, the overlap surface 445 limits or prevents rotational movement of the insert 500 about an axis that coincides with the load-bearing protrusion 570 and operates to assist in the placement of the insert 500 within the recess 430. As will be appreciated by those of ordinary skill in the art, there may be appropriate tolerances between the dimensions of the rail 442 and the insert 500 to facilitate sliding of the insert 500 relative to the frame body 410 and avoid sticking. The spacing of the overlapping surfaces 445 also allows the front surface 510 of the insert 500 to reside directly adjacent to the frame plane "P", allowing the rear surface 412 of the frame body 410 to remain substantially flush with the wall. The insert plate 500 may also include activated or activatable features to frictionally engage one or more surfaces of the substrate 400.

Both the frame body 410 and the insert plate 500 include one or more pairs of insert guides 450, 550, each spaced across a given width, wherein each insert guide is adjacent to a respective side edge. The insert guides 450, 550 include an aperture extending through the plate or frame, respectively. Each aperture is sized and positioned to allow the curved fork 150 or shank 160 on the anchor 100 to reach the intended wall surface when the recess 430 fully receives the insert plate 500. The frame body 410 and the insert plate also include rotation apertures 490, 590, each adjacent to the respective top edge 413, 513; the rotation apertures 490, 590 are sized to receive the arcuate tab 190 on the top edge 113 of the anchor 100. The rotational holes 490, 590 cooperate with the arcuate tabs 190 to align the curved fingers 150 relative to the insertion guides 450, 550 and facilitate proper rotational insertion of the anchor into the wall. One of ordinary skill in the art will appreciate that the anchor 100, frame 400, and insert 500 may be assembled without the use of rotational apertures or arcuate tabs.

To assemble the anchor assembly 40, the user or manufacturer may slide or otherwise move the insert plate 500 through the insert guide until the bottom edge engages or otherwise abuts the rail 448 and the insert guides 450, 550 are aligned. Next, the spacer pad 300 is secured to the front face 511 of the insert plate 500 beneath the load bearing projection 570. One or both of these steps may be performed by the manufacturer or retailer so that the user is not involved in the initial assembly. The anchor 100 remains separated until later in the anchor assembly installation process.

A method of using the wall anchor assembly 40 is illustrated in FIGS. 12a-12h. In a first step, a partially assembled anchor assembly 40 is provided, featuring an insert 500 received in a recess and a spacer pad 300 removably secured to a front face 511. (FIG. 12A). Next, a mounting object (here depicted as a wire 700) is placed on a load bearing structure 570 via, for example, a wire, bracket, or D-ring, and the front surface 310 of the pad 300 is attached to the object (FIG. 12B). The user can position and orient the assembly at a desired location on the wall surface by directly moving (e.g., sliding or rotating) the mounting object (FIG. 12C). Once the user is satisfied with the position of the object, the user applies pressure on the object to adhere the assembly 40 to the wall. If a repositionable adhesive configuration is used, the user may choose to first secure the frame to the wall and then move it to the desired position. The insert plate 500 may then be removed from the frame 400 by moving the object in the direction of the top edge 413 of the frame body (FIG. 12D). After confirming that the frame 400 is in the correct position and orientation, the user returns the insert plate 500 to the recess 430. (FIG. 12E). The arched tab 190 on the anchor 100 is then placed in the rotational aperture 490, 590, or the anchor is otherwise aligned with the frame/insert plate assembly (FIG. 12F), and the anchor 100 is rotationally inserted into the wall. (FIG. 12G). Once the anchor is substantially flush with the front surface 511 of the insert plate 510, the object may be secured to the load bearing structure 570 again (FIG. 12H). Not all of these steps are necessary for all objects or all wall surfaces to be mounted.

Once assembled in final form on the wall, the upper surface of the guide aperture 550 of the insert plate is substantially disposed on (i.e., vertically supported by) the curved fingers 150 of the anchor 100. Alternatively, the lower surface of the load bearing structure 570 is disposed on a portion of the anchor aperture 180. The insert plate 500 will thus be rotationally restrained, and loads from the mounting object on the insert plate can be effectively transferred to the anchor 100 and the wall without rotating the fingers 150 through and off the wall plate.

Turning to Figures 13 to 16, another pivotable wall anchor assembly is depicted. The wall anchor assembly includes a base plate 610 pivotally coupled to two insert plates: an upper insert plate 630 and a lower insert plate 640 at opposing hinge sections 628 and 629. Each insert plate 630, 640 includes a pair of curved fingers 650, 660, respectively. It should be understood that many other aspects of the anchor assembly may have similar form and function as described with respect to anchor 100, and these need not be repeated.

The upper insert plate 630 includes fingers 650 that are bent in the direction of the hinge section 628. The fingers 650 are positioned on the side edges 635, 636 of the upper plate 630 at a location near the distal edge 634 of the plate. The fingers 650 are spaced across the distal edge 634 so that the distance between the fingers is greater than the width of the base plate 610. In other embodiments, the base plate may feature guides similar to those of the anchor assembly 40, wherein apertures in the base plate 610 are spaced to receive the fingers 650. The distal edge 634 also includes an upper section 670a that carries the bearing projection 670. The distance between the hinged section 628 and the distal edge 634 is approximately equal to the distance between the hinged section 628 and the central transverse axis 619 of the substrate 610.

The lower insert plate 640 includes fingers 660 that bend in the direction of the hinge section 629 or bend downward relative to the fingers 650. The fingers 660 are positioned on the side edges 645, 646 of the lower plate 640 at a location near the distal edge 644 of the plate. The fingers 660 are spaced across the distal edge 644 so that the distance between the fingers is greater than the width of the substrate 610. The distal edge 644 also includes a lower section 670b of the load-bearing protrusion 670. The distance between the hinge section 629 and the distal edge 644 is approximately equal to or less than the distance between the hinge section 629 and the central transverse axis 619 of the substrate 610.

Due in part to the presence of the two sets of curved fingers 650, 660, the wall anchor assembly can be secured to a wall using hinge sections 628, 629 oriented vertically or horizontally (or at an oblique angle relative to the central axis 619). Multiple orientations allow the user to accommodate various spatial constraints where a vertical orientation may not be feasible. The rear surface 621 of the substrate 610 can also feature a removable, positionable, and/or repositionable adhesive structure. The wall anchor assembly can also be used to create a vague mark on the wall using the outer ends 652, 662 of the fingers, allowing the user to determine the position and orientation of the assembly on the wall surface without fully inserting the fingers 650, 660. Once confirmed, the user can rotate both the upper and lower insert plates to insert the fingers 650, 660 until the insert plates 630, 640 are substantially flush with the base plate 610 and the load bearing sections 670a, 670b are assembled to provide the load bearing structure 670.

Although depicted as having two interposers 630, 640, the assembly may feature three or more interposers pivotably coupled to the substrate 610. The additional interposers may be configured in columns, rows, grids, or radial arrays, as some non-limiting examples. Some or all of the additional interposers may be configured in opposing pairs; in other embodiments, some or all of the features may be in a discrete orientation relative to the other panels. Some or all of the additional interposers may include load bearing segments that combine to form a load bearing structure, including in combination with a load bearing segment on the substrate.

The disclosed wall anchor assembly may be used even in situations where the object does not include a wire but instead includes a different backing hardware configuration. Exemplary backing hardware configurations include, but are not limited to, a "D" ring, sawtooth, keyhole hanger, etc.

FIG. 17 illustrates an embodiment of a wall anchor kit for mounting an object according to the present disclosure. The kit features a transfer structure 800 having a removable and/or (re)positionable adhesive structure of the type described above on opposing front and rear major surfaces. The transfer structure 800 may include alignment features 810 configured to reside adjacent to or within backing hardware and/or to position the load bearing structure on a wall anchor in a correct position to engage the backing hardware. The transfer structure 800 generally includes different adhesive properties between the structures on the front surface and the back surface because the adhesive structure on the front surface (i.e., the surface intended to be attached to the object) generally forms a weaker bond with the object than the adhesive structure on the back surface forms with a wall panel or other wall surface. Therefore, the object can be removed (e.g., peeled off) from the transfer structure 800 without removing the structure from the wall. The transfer structure can be formed of any of the materials used to build the pillow frames or spacers described herein, for example, or any other material suitable for the intended purpose.

A kit may include, for example, two wall hangers and six transfer structures of the type described herein, although the exact number of any component in the kit is not limited. Alternatively, a kit may include only two or more transfer structures. The transfer structures may also be used in a kit in conjunction with or provided by common hardware, such as nails, screws, and other forms of wall anchors.

In use, the transfer structure 800 can be secured to the back of an object (such as the picture frame 900 in FIG. 17 ). The transfer structure 800 is positioned on the object so that the alignment feature 810 is aligned with the backing hardware or other desired location for engaging a wall anchor or conventional fastener (e.g., nail, screw, etc.). In FIG. 17 , for example, the point 815 at the end of the alignment feature 810 is positioned within the D-ring recess 910. Once the user is satisfied with the position of the object (frame 900), the user applies pressure on the object to adhere the rear surface of one or more transfer structures 800 to the wall. If a repositionable or positionable adhesive structure is used on the rear surface, the user may choose to first adhere the transfer structure to the wall and then move it to the desired location. The inserted object can then be removed from the front surface of the transfer structure 800 by peeling or other mechanism. After confirming that the transfer structure 800 is in the correct position and orientation, the user aligns a wall anchor (such as wall anchor 100) and the accompanying load bearing structure with each transfer structure. The anchor(s) can be inserted into the wall. Once the anchor (or other fastener) reaches the desired location within the wall, the object can be secured to the load bearing structure.

Another embodiment of the transfer structure concept is shown in FIG. 18 and FIG. 19. The transfer structure 1000 includes a first adhesive transfer structure 1010 and a second adhesive transfer structure 1020. The first adhesive structure 1010 includes a backing layer 1012 and an adhesive layer 1014, and the adhesive layer is on a main surface of the backing layer 1012. The second adhesive structure 1020 also includes a backing layer 1022 and an adhesive layer 1024, and the adhesive layer has the same or different adhesive composition as the first adhesive structure and is on a main surface of the backing layer 1022. Each adhesive layer 1014, 1024 can be a single layer or multiple layers. Each backing 1012, 1022 may be monolayer or multilayer. Adhesive layers 1014, 1024 may be identical to one another or distinct from one another. In this context, distinct is used to describe a substantial difference in composition or adhesive properties. Adhesive layers 1014, 1024 may each be continuous or discontinuous (e.g., patterned) across the major surface of the necessary backing. The structures have an overall generally circular shape in a plane perpendicular to the backing surface. In other embodiments, the structures present another shape or combination of shapes in the same viewing direction, including a rectangle (including a square), an oval, a triangle, a tetrahedron, a Y-shape, etc. Other variations may be conceived and discerned by those of ordinary skill in the art.

The adhesive transfer structures 1010, 1020 may include an alignment aperture 1080 at the center of each. The alignment aperture 1080 may be used to align with backing hardware or to mark a desired location on a wall surface for placing a wall anchor or conventional fastener (e.g., nail, screw, etc.). The alignment aperture 1080 may share the shape of the corresponding structure (as shown, both are circular) or may be different. The adhesive transfer structure may include multiple alignment features, such as aperture 1080 and notches (not shown). The notches may be used to align features on the transfer structure with notches 123 or similar features on the wall anchor 100 and indicate a location for marking a wall.

The outer surfaces of the adhesive layers 1014, 1024 of the first adhesive transfer structure 1010 and the second adhesive transfer structure 1020 can be used to adhere the transfer structure to a desired attachment, hardgood, and/or mounting object (e.g., a picture frame). One or both of the available adhesive layers 1014, 1024 can be covered by a release pad (not shown).

The first adhesive configuration 1010 and the second adhesive configuration 1020 may include a backing as depicted or may be backingless. Backingless (i.e., carrier-free) adhesive configurations are described, for example, in U.S. Publication No. 2016/0068722 (Schmitz-Stapela et al.). As an alternative to a backing-bearing adhesive configuration, a backingless or solid adhesive may be used in place of a backing and adhesive layer combination in either or both of the first adhesive configuration 1010 and the second adhesive configuration 1020. An unbacked adhesive construction itself may comprise a plurality of adhesive materials provided as sub-layers or mixtures or otherwise, and may be provided in a manner such that an adhesive surface is the same or different from other surfaces of the adhesive. For example, two different adhesive compositions may be co-extruded to provide an adhesive construction comprising two different sub-layers, one forming a first adhesive surface having a first desired adhesion to a substrate, and the other forming a second adhesive surface having a second desired adhesion. The desired adhesions may be the same or different, allowing, for example, one to be at least semi-permanent and the other to be removable without damage.

A backing, if used, may be a single layer or multi-layer construction. The materials forming the backing may include paper, natural or synthetic polymer films, nonwovens made from natural and/or synthetic fibers and combinations thereof, warp reinforced polymer films, warp or yarn reinforced polymer films or nonwovens, fabrics (such as woven fabrics formed from yarns of synthetic or natural materials). The backing may also be formed from metal, metallized polymer films, or ceramic sheet materials in combination with at least one of the above. In some embodiments, the backing is a multi-layer film having two or more layers; in some such embodiments, the layers are laminated. For example, the backing may be formed from a foam, a film, or a combination thereof, having any suitable thickness, composition, and opacity or transparency.

The transfer structure 1000 includes a separable connection system between a first adhesive transfer structure 1010 and a second adhesive transfer structure 1020. The separable connection system includes a first connector member 1030 and a second connector member 1040, wherein the first connector member is disposed on the second major surface of the first adhesive structure 1010 and the second connector member is disposed on the second major surface of the second adhesive structure 1020. The first and second separable connector members 1030, 1040 can be engaged with each other to form a separable connection, thereby removably connecting the transfer structures 1010, 1020: after the separable connection 1030 is separated, the first connector member 1030 is maintained with the first adhesive structure 1010, and the second connector member 1040 is maintained with the second adhesive structure 1020. Certain advantages of the article are based on the incorporation of the separable connection 1030 between the first adhesive structure 1010 and the second adhesive structure 1020, because a mounting object can be separated from a mounting surface without destroying either of the adhesive transfer structures 1010 or 1020. The first connector member 1030 and the second connector member 1040 are generally coextensive with the adhesive layers and cover areas similar to those of the adhesive layers.

The user may utilize any (multiple) suitable techniques to appropriately reconnect the first detachable connecting member 1030 and the second detachable connecting member 1040.

The separable connection may include any known or developed reusable connector for connecting adhesive transfer structures 1010, 1020. The separable connection 1030 allows the first adhesive structure 1010 and the second adhesive structure 1020 to be separated and connected along a general plane. In some embodiments, the separable connection may include, for example, a mechanical fastener including an interlocking system, a mutual engagement system with a connection without visible mechanical deformation or interference, a releasable contact response fastener, a divisible structure, and the like. In other embodiments, the separable connector includes one or more layers of an adhesive, a gel, or a gel-adhesive that are bonded by covalent bonding, ionic bonding, hydrogen bonding, and/or Van der Waals forces.

In some embodiments, the first separable connecting member 1030 may include a layer of hook material, and the second separable connecting member 1040 may also include a layer of hook or loop material. It is contemplated that any commercially available hook and loop connector system may be used, including those available from 3M Company. The hook and loop connector system is only one type of mechanical interlocking connector system suggested by the present embodiment. By mechanical interlocking is meant that at least one of the connector elements of the fastener undergoes some visible deformation (preferably plastic deformation) such that a mechanical interference is formed between the plurality of components. Many different modifications of the design of these interlocking elements are based on the forces and methods necessary to separate the cooperating layers of this separable connector system. Some exemplary separable connectors are described, for example, in the following: U.S. Patent Nos. 6,572,945; 7,781,056; 6,403,206; and 6,972,141, all of which are incorporated herein by reference in their entirety.

The separable connecting members 1030, 1040 may be connected to the adhesive structures 1010, 1020 using any (multiple) suitable techniques. In one or more embodiments, the separable connecting members 1030, 1040 are adhered to the necessary adhesive structures using any suitable adhesive or adhesive combination (including any of the hot melt adhesives further described herein). Further, in one or more embodiments, the separable connecting members 1030, 1040 may be ultrasonically bonded to the necessary adhesive structures 1010, 1020. In one or more embodiments, the separable connecting members 1030, 1040 may be mechanically attached to the necessary adhesive structures using any (multiple) suitable techniques. In one or more embodiments, a connecting layer as described in any of the embodiments herein may be disposed between one or both of the first connecting member 1030 and the second connecting member 1040 and the first adhesive structure 1010 and the second adhesive structure 1020, respectively.

In use, the transfer structure 1000 can be secured to the back of an object. The transfer structure 1000 is positioned on the object so that the alignment features are aligned with the backing hardware or other desired location for engaging a wall anchor or conventional fastener (e.g., nail, screw, etc.). Once the user is satisfied with the position of the object, the user applies pressure on the object to adhere the rear surface of one or more transfer structures to the wall. If a repositionable or positionable adhesive structure is used on the rear surface, the user may choose to first adhere the transfer structure to the wall and then move it to the desired location. The object can then be removed from the front surface of the transfer structure at the removable interface. After confirming that the transfer structure is in the correct position and orientation, the user can use the alignment feature (e.g., notch or aperture 1080) to mark the desired location of a corresponding feature of an anchor or other fastener on the wall. The user then aligns a wall anchor (such as wall anchor 100) or other fastener with either the alignment feature or a mark made on the wall using the alignment feature. The anchor(s) or fastener(s) can be inserted into the wall. Once the anchor (or other fastener) reaches the desired location in the wall, the object can be secured to a load bearing structure.

Notably, the transfer structure(s) described above may adopt the shape and characteristics of the pillow frame 200 described above, whether or not the pillow frame has an insertion guide 240. Such a pillow frame (e.g., one including a detachable connection system and one or more adhesive surfaces) may include one or more alignment features, and in a specific embodiment, includes both an alignment aperture and an alignment notch on an edge of the pillow frame to facilitate marking the wall.

A wall anchor 2000 according to another embodiment of the present disclosure is depicted in FIGS. 20-22. Unless specifically stated otherwise, the considerations and components of anchor 2000 are the same as those of anchor 100 and need not be repeated here. Wall anchor 2000 includes a substrate 2010 that exhibits a generally rectangular shape (as seen in FIG. 22). The substrate 2010 includes a front surface 2011 that is opposite a rear surface 2012 facing the wall; a top edge 2013; a bottom edge 2014; and opposite side edges 2015, 2016 that connect the top edge 2013 and the bottom edge 2014 to define an outer panel perimeter. A pair of downwardly curved fingers 2050 extend from each side edge 2015, 2016 in a direction generally orthogonal to the rear surface 2012. The fingers 2050 extend to an outer end that may be tapered to facilitate insertion when pressed into a wall panel or other mounting surface. The wall anchor 2000 (or a plurality of wall anchors 2000) may also be pivotally coupled to a base.

The method of insertion and removal for wall anchor 2000 (and other anchors featuring downwardly curved fingers) is essentially the reverse of the method depicted in FIGS. 6A and 6B, as the anchor is rotated about an axis closer to bottom edge 2013 to insert and remove fingers 2050.

The wall anchors and anchor assemblies disclosed herein can be used to mount numerous items and objects to surfaces such as painted drywall, stucco, concrete, glass, ceramic, fiberglass, metal, or plastic. Items that can be mounted include, but are not limited to, wall shelving, storage racks, stands, baskets, containers, decorations (e.g., holiday decorations), calendars, posters, dispensers, wire clips, guitars, floating shelves, curtain rods, heavy-duty hooks, brackets, wall lamps, and handles.

Embodiment

1. A wall anchor assembly, comprising: a wall anchor including a base plate and a first fork; and a pillow frame having an adhesive structure on a main surface thereof.

2. A wall anchor assembly as in Example 1, wherein the adhesive structure is at least one of positionable and repositionable.

3. A wall anchor assembly as in Example 1 or 2, wherein the adhesive structure is stretchable and releasable.

4. A wall anchor assembly as in Examples 1 to 3, wherein the pillow frame is compressible.

5. The wall anchor assembly of Examples 1 to 4, further comprising a spacer pad, the spacer pad being integral with at least a portion of the pillow frame.

6. The wall anchor assembly of Examples 1 to 5, wherein the base comprises opposite side edges, and wherein the base of the interdigitated finger is integral with one of the opposite side edges.

7. A wall anchor assembly as in Examples 1 to 6, wherein the base further comprises a hook, and wherein the bottom of the hook is disposed in a plane parallel to or higher than a top edge of a base of the interdigitated finger.

8. A wall anchor assembly as in Examples 1 to 6, wherein the fork finger bends upward or downward in the direction of the top edge.

9. A wall anchor assembly as in any one of Examples 1 to 8, further comprising a second curved fork finger extending outwardly along an arc to an outer end.

10. The wall anchor assembly of Example 9, wherein the outer end of the first fork finger is coplanar with the outer end of the second fork finger.

11. A wall anchor assembly as in Example 10, wherein each of the fingers bends upward or downward in the direction of a top edge of the base plate.

12. A wall anchor assembly as in any one of embodiments 1 to 11, wherein the bracket includes at least one insertion guide for receiving the fork finger.

13. A wall anchor assembly as in any one of embodiments 1 to 12, wherein the base comprises a front surface and a rear surface, and wherein when the assembly is assembled, the rear surface of the base is flush with the front surface of the frame.

14. A wall anchor assembly as in Example 13, wherein the spacer pad includes a front surface and a rear surface, and wherein when the anchor assembly is assembled, the rear surface of the spacer pad is flush with the front surface of the base plate.

15. A wall anchor assembly as in Example 14, wherein the rear surface of the spacer pad includes a detachable interface.

16. The wall anchor assembly of any of the preceding embodiments, wherein the base of the interdigitated finger has a height measured along a side edge of the substrate and a thickness measured along a top edge of the substrate, and wherein the height is at least twice the thickness.

17. The wall anchor assembly of embodiment 16, wherein the height is at least three times the thickness.

18. A wall anchor assembly comprising: a frame having a front surface and a rear surface, the frame including a guide on the front surface thereof, the guide configured to receive an insert plate, the insert plate including a load bearing structure; an anchor including a curved finger having a base, wherein the finger extends outwardly along an arc to an outer end through the wall; and wherein the rear surface of the base includes an adhesive structure.

19. A wall anchor assembly as in Example 18, wherein the base plate is pivotally coupled to the insert plate at a first hinge section.

20. A wall anchor assembly as in Example 19, wherein the first hinge section is disposed adjacent to a top edge of the base plate and a proximal edge of the insert plate.

21. The wall anchor assembly of Example 18, wherein the base includes a guide aperture sized to receive the interdigitated finger.

22. The wall anchor assembly of Examples 18 to 21, wherein the frame includes a recess, and wherein a portion of the insert plate is sized to fit within the recess.

23. The wall anchor assembly of embodiment 18, wherein the base of the interdigitated finger has a height measured along the side edge and a thickness measured along the top edge, and wherein the height is at least twice the thickness.

24. The wall anchor assembly of embodiment 23, wherein the height is at least three times the thickness.

25. A wall anchor assembly as in Example 18, wherein the fork finger bends upward or downward in the direction of the proximal edge.

26. A wall anchor assembly as in Example 18, further comprising a second curved fork finger extending outwardly along an arc to an outer end.

27. The wall anchor assembly of Example 26, wherein the outer end of the first fork finger is coplanar with the outer end of the second fork finger.

28. The wall anchor assembly of embodiment 26, wherein the base of the second finger is integral with one of the opposite side edges.

29. The wall anchor assembly of embodiment 28, wherein the base of the second finger is integral with the side edge opposite to the side edge integral with the base of the first finger.

30. The wall anchor assembly of Example 18, wherein the adhesive structure is at least one of positionable or repositionable.

31. A wall anchor assembly as in Examples 18 to 30, wherein the guide comprises two or more rails, and wherein the rails comprise a guide surface acting on a front face of the insert plate.

32. A wall anchor assembly comprising: a base plate including opposing major surfaces; a first insert plate pivotally coupled to an edge of the base plate at a first hinge section; a second insert plate pivotally coupled to the base plate at a second hinge section, the second hinge section being disposed at an edge of the base plate opposite the first hinge section; and an adhesive structure on a major surface of the base plate, wherein each insert plate includes a curved interdigital finger extending from a surface of the respective insert plate at a location distal to the hinge section.

33. The wall anchor assembly of embodiment 32, wherein when the first insert plate and the second insert plate are pivoted to be adjacent to a main surface of the substrate, the interdigitated fingers bend in opposite directions.

34. A method for mounting an object, the method comprising: providing an anchor assembly as in any one of embodiments 1 to 33; temporarily attaching a rear surface of the assembly to a wall at a first position; placing the object on a load-bearing structure of the anchor assembly; directly manipulating the object so that the anchor assembly is disposed at a second position; and removing the object from the load-bearing structure.

35. The method of embodiment 34, further comprising using a finger of the anchor assembly to establish a positioning mark on the wall adjacent to the second position.

The patents, patent documents, and patent applications cited herein are incorporated herein by reference in their entirety, just as each of the above documents is individually incorporated by reference. It will be apparent to those of ordinary skill in the art that various changes and modifications may be made without departing from the above invention concepts. Therefore, the scope of this disclosure should not be limited to the structures described herein. Those of ordinary skill in the art will understand that many changes may be made to the above embodiments and implementations without departing from the basic principles thereof. Furthermore, various modifications and alterations in the present invention will be apparent to those of ordinary skill in the art and do not depart from the spirit and scope of the present invention. Therefore, the scope of this application shall be determined solely by the scope of the following patent applications and their equivalents.

610: Substrate

628: Hinge section

629: Hinge section

630: Upper insert plate/insert plate/upper plate

634: Remote edge

635: Side edge

636: Side edge

640: Lower insert plate/insert plate/lower plate

645: Side edge

646: Side edge

650: Curved fork/fork

660: Curved fork/fork

670a: Upper section/load bearing section

670b: Lower section/load bearing section

Claims (6)

A kit includes a wall anchor; and one or more transfer structures, each transfer structure including a separable connection system and a marking aperture, wherein each of the transfer structures includes: a first adhesive layer and a first separable connector assembly coupled to the first adhesive layer; and a second adhesive layer and a second separable connector assembly, wherein the first separable connector assembly and the second separable connector assembly can be engaged with each other to form the separable connection system. A kit as claimed in claim 1, wherein the wall anchor comprises a base plate including opposing front and rear surfaces, a top edge, a bottom edge, and two opposing side edges; and a first curved finger having a base, wherein the first curved finger extends outwardly along an arc to an outer end through the wall, and wherein the base of the first curved finger is integral with one of the opposing side edges. A set as claimed in claim 2, wherein the wall anchor further comprises a second curved finger extending outwardly along an arc to an outer end, wherein the outer end of the first curved finger and the outer end of the second curved finger are coplanar, and wherein each finger bends downwardly in the direction of the bottom edge. A kit as claimed in claim 1, wherein the first separable connector component comprises a hook material, and wherein the second separable connector component comprises at least one or a hook material or a loop material. A kit as claimed in claim 1, wherein, when the transfer structure is assembled, the first adhesive layer and the second adhesive layer define opposing major surfaces of the transfer structure. A kit as claimed in claim 1, wherein the wall anchor comprises a base plate including opposing front and rear surfaces, a top edge, a bottom edge, and two opposing side edges; and a curved finger having a base, wherein the finger extends outwardly along an arc to an outer end through the wall, and wherein the base of the curved finger is integral with one of the opposing side edges, and the kit further comprises a pillow frame including an aperture for receiving the curved finger.

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